Contamination and defect resistant optical encoder configuration outputting structured illumination to a scale plane for providing displacement signals

ABSTRACT

An optical encoder configuration comprises a scale, an illumination source, and a photodetector configuration. The illumination source is configured to output structured illumination to the scale. The scale extends along a measuring axis direction and is configured to output scale light that forms a detector fringe pattern comprising periodic high and low intensity bands that extend over a relatively longer dimension along the measuring axis direction and are relatively narrow and periodic along a detected fringe motion direction transverse to the measuring axis direction. The high and low intensity bands move along the detected fringe motion direction transverse to the measuring axis direction as the scale grating displaces along the measuring axis direction. The photodetector configuration is configured to detect a displacement of the high and low intensity bands along the detected fringe motion direction and provide respective spatial phase displacement signals that are indicative of the scale displacement.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/637,750, entitled “CONTAMINATION AND DEFECT RESISTANTOPTICAL ENCODER CONFIGURATION FOR PROVIDING DISPLACEMENT SIGNALS,” filedJun. 29, 2017, the disclosure of which is hereby incorporated herein byreference in its entirety.

BACKGROUND

Technical Field

The invention relates generally to precision position or displacementmeasurement instruments, and more particularly to an encoderconfiguration with signal processing which is resistant to errors thatmay be associated with a contaminated or defective portion of a scale.

Description of the Related Art

Optical position encoders determine the displacement of a readheadrelative to a scale that includes a pattern that is detected by thereadhead. Typically, position encoders employ a scale that includes atleast one scale track that has a periodic pattern, and the signalsarising from that scale track are periodic as a function of displacementor position of the readhead along the scale track. Absolute typeposition encoders may use multiple scale tracks to provide a uniquecombination of signals at each position along an absolute scale.

Optical encoders may utilize incremental or absolute position scalestructures. An incremental position scale structure allows thedisplacement of a readhead relative to a scale to be determined byaccumulating incremental units of displacement, starting from an initialpoint along the scale. Such encoders are suitable for certainapplications, particularly those where line power is available. In lowpower consumption applications (e.g., battery powered gauges and thelike), it is more desirable to use absolute position scale structures.Absolute position scale structures provide a unique output signal, orcombination of signals, at each position along a scale, and thereforeallow various power conservation schemes. U.S. Pat. Nos. 3,882,482;5,965,879; 5,279,044; 5,886,519; 5,237,391; 5,442,166; 4,964,727;4,414,754; 4,109,389; 5,773,820; and 5,010,655 disclose various encoderconfigurations and/or signal processing techniques relevant to absoluteposition encoders, and are hereby incorporated herein by reference intheir entirety.

Some encoder configurations realize certain advantages by utilizing anillumination source light diffraction grating in an illumination portionof the encoder configuration. U.S. Pat. Nos. 8,941,052; 9,018,578;9,029,757; and 9,080,899, each of which is hereby incorporated herein byreference in its entirety, disclose such encoder configurations. Some ofthe configurations disclosed in these patents may also be characterizedas utilizing super resolution moiré imaging.

In various applications, scale manufacturing defects or contaminantssuch as dust or oils on a scale track may disturb the pattern detectedby the readhead, creating errors in the resulting position ordisplacement measurements. In general, the size of errors due to adefect or contamination may depend on factors such as the size of thedefect or contamination, the wavelength of the periodic pattern on thescale, the size of the readhead detector area, the relationship betweenthese sizes, and the like. A variety of methods are known for respondingto abnormal signals in an encoder. Almost all such methods are based ondisabling the encoder signals, or providing an “error signal” to warnthe user, or adjusting a light source intensity to boost low signals, orthe like. However, such methods do not provide a means of continuingaccurate measurement operations despite the abnormal signals that arisefrom certain types of scale defects or contamination. Therefore, thesemethods have limited utility. One known method that does mitigate theeffects of scale contaminants or defects on measurement accuracy isdisclosed in Japanese Patent Application JP2003-065803 (the '803Application). The '803 Application teaches a method wherein two or morephoto detectors output periodic signals having the same phase, which areeach input to respective signal stability judging means. The signalstability judging means only outputs signals that are judged to be“normal,” and “normal” signals are combined as the basis for positionmeasurement. Signals that are “abnormal” are excluded from positionmeasurement calculations. However, the methods of judging “normal” and“abnormal” signals disclosed in the '803 Application have certaindisadvantages that limit the utility of the teachings of the '803Application.

U.S. Pat. No. 8,493,572 (the '572 patent) discloses a contamination anddefect resistant optical encoder configuration which provides a means toselect signals from photodetector elements which are not subject tocontamination. However, the '572 patent relies on complex signalprocessing that may be less desirable in some applications.

Improved methods for providing accurate measurement operations thatavoid or mitigate abnormal signals that arise from certain types ofscale defects or contamination without the need for complex signalprocessing would be desirable.

BRIEF SUMMARY

A contamination and defect resistant optical encoder configuration forproviding displacement signals is disclosed. The contamination anddefect resistant optical encoder configuration comprises a scale, anillumination source, and a photodetector configuration. The scaleextends along a measuring axis direction, and comprises a scale gratingcomprising grating bars arranged in a scale plane that is nominallyparallel to the measuring axis direction, wherein the grating bars arenarrow along the measuring axis direction and elongated along a gratingbar direction transverse to the measuring axis direction, and arearranged periodically at a scale pitch P_(SF) along the measuring axisdirection. The illumination source comprises a light source that outputslight, and a structured illumination generating portion configured toinput the light and output structured illumination to an illuminationregion at the scale plane where the structured illumination comprises anillumination fringe pattern comprising fringes that are narrow along themeasuring axis direction and elongated along an illumination fringedirection oriented transverse to the measuring axis direction at anonzero illumination fringe yaw angle relative to the grating bardirection. The photodetector configuration comprises a set of N spatialphase detectors arranged periodically at a detector pitch PD along adetected fringe motion direction transverse to the measuring axisdirection, wherein each spatial phase detector is configured to providea respective spatial phase detector signal and at least a majority ofthe respective spatial phase detectors extend over a relatively longerdimension along the measuring axis direction and are relatively narrowalong the detected fringe motion direction transverse to the measuringaxis direction, and the set of N spatial phase detectors are arranged ina spatial phase sequence along the detected fringe motion direction. Thescale grating is configured to input the illumination fringe pattern atthe illumination region and output scale light that forms a detectorfringe pattern at the photodetector configuration, the detector fringepattern comprising periodic high and low intensity bands that extendover a relatively longer dimension along the measuring axis directionand are relatively narrow and periodic with a detected fringe period PDFalong the detected fringe motion direction transverse to the measuringaxis direction. The detected fringe period PDF and the detected fringemotion direction transverse to the measuring axis depend at leastpartially on the nonzero illumination fringe yaw angle. The high and lowintensity bands move along the detected fringe motion directiontransverse to the measuring axis direction as the scale gratingdisplaces along the measuring axis direction. The photodetectorconfiguration is configured to detect a displacement of the high and lowintensity bands along the detected fringe motion direction transverse tothe measuring axis direction and provide respective spatial phasedisplacement signals that are indicative of the scale displacement.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the attendant advantages will becomemore readily appreciated as the same become better understood byreference to the following detailed description, when taken inconjunction with the accompanying drawings, wherein:

FIG. 1 is a partially schematic exploded diagram of a contamination anddefect resistant optical encoder configuration for providingdisplacement signals.

FIG. 2 is a partially schematic diagram of a contamination and defectresistant optical encoder configuration for providing displacementsignals.

FIG. 3 is a partially schematic diagram of a photodetector configurationof a contamination and defect resistant optical encoder configuration.

FIG. 4A is a schematic diagram of a portion of a photodetectorconfiguration of a contamination and defect resistant optical encoderconfiguration.

FIG. 4B is a schematic diagram of a portion of a photodetectorconfiguration of a contamination and defect resistant optical encoderconfiguration.

FIG. 5 is a partially schematic diagram of an additional implementationof a contamination and defect resistant optical encoder configurationfor providing displacement signals, wherein a detector fringe patternmoves transverse to the measuring axis direction during optical encoderdisplacement.

FIG. 6A is a schematic diagram representing a first view of scale lightcomponents that form a detector fringe pattern proximate to aphotodetector configuration including spatial phase detectors that areelongated approximately along the measuring axis direction and arrangedperiodically transverse to the measuring axis direction.

FIG. 6B is a schematic diagram representing a second view of scale lightcomponents that form a detector fringe pattern proximate to aphotodetector configuration including spatial phase detectors that areelongated approximately along the measuring axis direction and arrangedperiodically transverse to the measuring axis direction.

FIG. 7 is a graph of properties of a contamination and defect resistantoptical encoder similar to the optical encoder represented in FIG. 5 andFIG. 6, including a detected fringe period versus an illumination fringeyaw angle.

FIG. 8 is a schematic diagram of one exemplary photodetectorconfiguration usable in a contamination and defect resistant opticalencoder similar to the optical encoder represented in FIG. 5 and FIG. 6,wherein the photodetector configuration includes spatial phase detectorsthat are elongated approximately along the measuring axis direction andarranged periodically transverse to the measuring axis direction.

FIG. 9A is a detailed schematic diagram of a section of anotherexemplary photodetector configuration of a contamination and defectresistant optical encoder which is similar to the photodetectorconfiguration shown in FIG. 8.

FIG. 9B is a detailed schematic diagram of a section of anotherexemplary photodetector configuration of a contamination and defectresistant optical encoder which is similar to the photodetectorconfiguration shown in FIG. 8.

DETAILED DESCRIPTION

FIG. 1 is a partially schematic exploded diagram of a contamination anddefect resistant optical encoder configuration 100 for providingdisplacement signals. The encoder configuration 100 comprises a scalegrating 110, an illumination portion 120, and a photodetectorconfiguration 160.

FIG. 1 shows orthogonal X, Y, and Z directions, according to aconvention used herein. The X and Y directions are parallel to the planeof the scale grating 110, with the X direction parallel to a measuringaxis direction MA (e.g., perpendicular to elongated pattern elements ofthe scale grating 110). The Z direction is normal to the plane of thescale grating 110.

In the implementation shown in FIG. 1, the scale grating 110 is atransmissive grating. The scale grating 110 extends along a measuringaxis direction MA, and comprises a periodic pattern comprising bars thatare narrow along the measuring axis direction MA and elongated along aperpendicular to the measuring axis direction MA (i.e., the Ydirection), and that are arranged periodically along the measuring axisdirection MA.

The illumination portion 120 comprises an illumination source 130, afirst illumination grating 140, and a second illumination grating 150.The illumination source 130 comprises a light source 131, and acollimating lens 132. The light source 131 is configured to outputsource light 134 to the collimating lens 132. The collimating lens 132is configured to receive the source light 134 and output collimatedsource light 134′ to the first illumination grating 140. The firstillumination grating 140 receives the source light 134′ and diffractsthe source light 134′ toward the second illumination grating 150. Thesecond illumination grating 150 receives the source light 134′ andfurther diffracts the source light 134′ toward the scale grating 110along a source light path SOLP. The scale grating 110 inputs the sourcelight 134′ along the source light path SOLP and outputs scale lightcomprising a periodic scale light pattern 135 along a scale light pathSCLP to the photodetector configuration 160. The photodetectorconfiguration 160 receives the periodic scale light pattern 135 from thescale grating 110 along the scale light path SCLP. The periodic scalelight pattern 135 displaces past the photodetector configuration 160corresponding to a relative displacement between the scale grating 110and the photodetector configuration 160 along the measuring axisdirection MA. An example of a photodetector configuration similar to thephotodetector configuration 160 is shown in detail FIG. 3. Thephotodetector configuration 160 comprises a set of N spatial phasedetectors arranged in a spatial phase sequence along a directiontransverse to the measuring axis direction MA (i.e., the Y direction),where N is an integer that is at least 6 and the spatial phase sequencecomprises two outer spatial phase detectors at a start and end of thesequence along the direction transverse to the measuring axis and aninterior group of spatial phase detectors located between the two outerspatial phase detectors. In the implementation shown in FIG. 1, the setof N spatial phase photodetectors comprises 3 subsets of spatial phasedetectors S₁, S₂, and S₃ that have the same subset spatial phasesequence.

At least a majority of the respective spatial phase detectors arerelatively elongated along the measuring axis direction MA andrelatively narrow along the direction perpendicular to the measuringaxis direction MA (i.e., the Y direction), and comprise scale lightreceptor areas that are spatially periodic along the measuring axisdirection MA and positioned corresponding to a respective spatial phaseof that spatial phase detector relative to the periodic scale lightpattern, and are configured to provide a respective spatial phasedetector signal. Each spatial phase detector in the interior group ispreceded and followed in the spatial phase sequence by spatial phasedetectors that have respective spatial phases that are different fromthat spatial phase detector and different from each other.

In various applications, the photodetector configuration 160 and theillumination portion 120 may be mounted in a fixed relationship relativeto one another, e.g., in a readhead or gauge housing (not shown), andare guided along the measuring axis direction MA relative to the scalegrating 110 by a bearing system, according to known techniques. Thescale grating 110 may be attached to a moving stage, or a gauge spindle,or the like, in various applications.

It should be appreciated that the contamination and defect resistantoptical encoder configuration 100 is only one example of a contaminationand defect resistant optical encoder configuration according to theprinciples disclosed herein. In alternative implementations, variousoptical components may be utilized such as a telecentric imaging system,limiting apertures, and the like. In alternative implementations, anillumination portion may comprise only a single illumination grating.

FIG. 2 is a partially schematic diagram of a contamination and defectresistant optical encoder configuration 200 for providing displacementsignals. The optical encoder configuration 200 is similar to the encoderconfiguration 100. Similar references numbers 2XX in FIGS. 2 and 1XX inFIG. 1 may refer to similar elements unless otherwise indicated bycontext or description. The encoder configuration 200 shown in FIG. 2 isa reflective configuration. Scale 210 is a reflective scale grating.

FIG. 3 is a partially schematic diagram of a photodetector configuration360 of a contamination and defect resistant optical encoderconfiguration 300. The contamination and defect resistant opticalencoder configuration 300 may be similar to the contamination and defectresistant optical encoder configuration 100 or the contamination anddefect resistant optical encoder configuration 200. The photodetectorconfiguration 360 comprises a set of N spatial phase detectors arrangedin a spatial phase sequence along a direction transverse to themeasuring axis direction MA, where N is an integer that is at least 6and the spatial phase sequence comprises two outer spatial phasedetectors at a start and end of the sequence along the directiontransverse to the measuring axis and an interior group of spatial phasedetectors located between the two outer spatial phase detectors. Atleast a majority of the respective spatial phase detectors arerelatively elongated along the measuring axis direction MA andrelatively narrow along the direction perpendicular to the measuringaxis direction MA, and comprise scale light receptor areas that arespatially periodic along the measuring axis direction MA and positionedcorresponding to a respective spatial phase of that spatial phasedetector relative to the periodic scale light pattern, and areconfigured to provide a respective spatial phase detector signal. Eachspatial phase detector in the interior group is preceded and followed inthe spatial phase sequence by spatial phase detectors that haverespective spatial phases that are different from that spatial phasedetector and different from each other.

In some implementations, the set of N spatial phase photodetectors maycomprise at least M subsets of spatial phase detectors, where M is aninteger that is at least 2, and wherein each of the M subsets includesspatial phase detectors that provide each of the respective spatialphases included in the set of N spatial phase photodetectors. In someimplementations, M may be at least 3. In some implementations, M may beat least 6. In some implementations, each of the M subsets of spatialphase detectors may comprise spatial phase detectors that provide thesame respective spatial phases arranged in the same subset spatial phasesequence. FIG. 3 shows an implementation with M subsets of spatial phasedetectors indicated as S₁ through S_(M). The subset S₁ comprises spatialphase detectors SPD_(1A), SPD_(1B), SPD_(1C), and SPD_(1D). The subsetS₂ comprises spatial phase detectors SPD_(2A), SPD_(2B), SPD₂, andSPD_(2D). The subset S_(M) comprises spatial phase detectors SPD_(MA),SPD_(MB), SPD_(MC), and SPD_(MD). Each of the spatial phase detectors inFIG. 3 is shown to have K scale light receptor areas. As an example ofscale light receptor areas, the spatial phase detector SPD_(MD) islabeled with scale light receptor areas SLRA_(M1) and SLRA_(MK). In someimplementations, K may be an even value.

In the implementation shown in FIG. 3, the spatial phase sequence isindicated by spatial phase detectors including subscript indices A, B,C, and D (e.g., the spatial phase detectors SPD_(1A), SPD_(1B),SPD_(1C), and SPD_(1D)). The spatial phase detectors with subscriptindices A and D are the two outer spatial phase detectors at the startand end of each instance of the spatial phase sequence. The spatialphase detectors with subscript indices B and C are the interior groups.

The spatial phase detectors SPD_(1A), SPD_(1B), SPD_(1C), and SPD_(1D)output respective spatial phase detector signals A₁, B₁, C₁, and D₁. Thespatial phase detectors SPD_(2A), SPD_(2B), SPD_(2C) and SPD_(2D) outputrespective spatial phase detector signals A₂, B₂, C₂, and D₂. Thespatial phase detectors SPD_(MA), SPD_(MB), SPD_(MC), and SPD_(MD)output respective spatial phase detector signals A_(M), B_(M), C_(M),and D_(M).

A contamination and defect resistant optical encoder configuredaccording to the principles disclosed herein provides a simple designwhich may be tolerant to contaminants (e.g., wirebonding contamination)which are as large as 100 micrometers and scale defects which are aslarge as 300 micrometers. Contaminants or defects on a scale willtypically produce a common mode error component on adjacent spatialphase detectors which may be canceled out in signal processing (e.g.,quadrature processing). Spatial phase detectors which are relativelyelongated along the measuring axis direction MA and relatively narrowalong the direction perpendicular to the measuring axis direction MAprovide better resistance to contamination and defects. Signal levelsmay change more slowly by decreasing the frequency of the structure ofthe spatial phase detectors along the measuring axis direction MA.Furthermore, such an encoder does not require complex signal processingto provide tolerance to contamination and defects. Signals provided bythe set of N spatial phase detectors may be processed according tostandard techniques known to one skilled in the art.

In some implementations such as the implementation shown in FIG. 3, N isat least 8 and each subset of spatial phase detectors may comprise 4spatial phase detectors having respective spatial phases separated by 90degrees. In alternative implementations, each subset of spatial phasedetectors may comprise 3 spatial phase detectors having respectivespatial phases separated by 120 degrees.

In the implementation shown in FIG. 3, the photodetector configuration360 includes connections configured to combine spatial phase detectorsignals corresponding to the same respective spatial phase and to outputeach such combination as a respective spatial phase position signal. Thephotodetector configuration 360 is configured to output 4 spatial phaseposition signals corresponding to spatial phases separated by 90degrees. Spatial phase signals with the same letter designation (e.g.,A₁, A₂, and A_(M)) are combined (e.g., summed) to provide spatial phasesignals ΣA, ΣB, ΣC, and ΣD. In alternative implementations, aphotodetector configuration may be configured to output 3 spatial phaseposition signals corresponding to spatial phases separated by 120degrees. In either case, spatial phase position signals may be furtherutilized to determine displacement signals, e.g., through quadrature orthree phase signal processing.

In some implementations, each of the respective spatial phase detectorsmay be relatively elongated along the measuring axis direction MA andrelatively narrow along the direction perpendicular to the measuringaxis direction MA, and may comprise scale light receptor areas that arespatially periodic along the measuring axis direction MA and positionedcorresponding to a respective spatial phase of that spatial phasedetector relative to the periodic scale light pattern, and may beconfigured to provide a respective spatial phase detector signal.

In some implementations, a dimension YSLRA of the scale light receptorareas of each of the N spatial phase detectors along the Y direction maybe at most 250 micrometers. In some implementations, YSLRA may be atleast 5 micrometers.

In some implementations, a separation distance YSEP between the scalelight receptor areas of each adjacent pair of the N spatial phasedetectors along the Y direction may be at most 25 micrometers.

In some implementations, a dimension YSLRA of the scale light receptorareas of each of the N spatial phase detectors may be the same along theY direction. In some implementations, a separation distance YSEP betweenthe scale light receptor areas of each adjacent pair of the N spatialphase detectors may be the same along the Y direction.

It should be appreciated that while a large value of N provides greaterrobustness to contamination, there is a tradeoff in that a large valueof N may provide smaller signal levels within each individual spatialphase detector.

FIG. 4A is a schematic diagram of a portion of a photodetectorconfiguration 460A of a contamination and defect resistant opticalencoder configuration 400A. For simplicity, FIG. 4A only shows onesubset of spatial phase detectors S₁ with two spatial phase detectorsSPD_(1A) and SPD_(1B). It should be appreciated that the photodetectorconfiguration 460A comprises at least six spatial phase detectorsaccording to the principles disclosed herein, but only two are shown forsimplicity. In the implementation shown in FIG. 4A, each of the Nspatial phase detectors (e.g., spatial phase detectors SPD_(1A) andSPD_(1B)) comprises a photodetector (e.g., photodetectors PD_(1A) andPD_(1B) indicated by dashed lines) covered by a spatial phase mask(e.g., phase masks PM_(1A) and PM_(1B)) that blocks the photodetectorfrom receiving the periodic scale light pattern except through openingsincluded in the spatial phase mask. In this case, the scale lightreceptor areas comprise areas of the photodetectors (e.g., thephotodetectors PD_(1A) and PD_(1B)) that are exposed through theopenings in the respective spatial phase masks (e.g., the spatial phasemasks PM_(1A) and PM_(1B)). In the implementation shown in FIG. 4A, thescale light receptor areas (i.e., the openings) of the phase maskPM_(1B) are offset relative to the scale light receptor areas of thephase mask PM_(1A) along the measuring axis direction MA by 90 degrees.It should be appreciated that the while the spatial phase masks PM_(1A)and PM_(1B) are schematically illustrated as separate portions in FIG.4A, in some implementations, they may be conveniently constructed withthe same material in the same process to eliminate any potentialpositioning errors.

FIG. 4B is a schematic diagram of a portion of a photodetectorconfiguration 460B of a contamination and defect resistant opticalencoder configuration 400B. For simplicity, FIG. 4B only shows onesubset of spatial phase detectors S₁′ with two spatial phase detectorsSPD_(1A)′ and SPD_(1B)′. It should be appreciated that the photodetectorconfiguration 460B comprises at least six spatial phase detectorsaccording to the principles disclosed herein, but only two are shown forsimplicity. In the implementation shown in FIG. 4B, each of the Nspatial phase detectors (e.g., spatial phase detectors SPD_(1A)′ andSPD_(1B)′) comprises a periodic array of electrically interconnectedphotodetector areas that receive the periodic scale light pattern. Inthis case, the scale light receptor areas comprise the photodetectorareas of the periodic array of photodetectors. In the implementationshown in FIG. 4B, the photodetector areas of the spatial phase detectorSPD_(1B)′ are offset relative to the photodetector areas of the spatialphase detector SPD_(1A)′ along the measuring axis direction MA by 90degrees.

FIG. 5 is a partially schematic diagram of an additional implementationof a contamination and defect resistant optical encoder configuration500 for providing displacement signals. In the encoder configuration500, the periodic scale light pattern 535 that is detected comprises adetector fringe pattern 535, which includes bands that are oriented toextend over a relatively longer dimension along the measuring axisdirection MA, and that move transverse to the measuring axis directionalong a detected fringe motion direction DFMD during optical encoderdisplacement.

The optical encoder configuration 500 comprises a scale 510, anillumination source 520, and a photodetector configuration 560. Thescale 510 extends along a measuring axis direction MA, and comprises ascale grating comprising grating bars GB arranged in a scale plane SPthat is nominally parallel to the measuring axis direction MA, whereinthe grating bars GB are narrow along the measuring axis direction MA andelongated along a grating bar direction GBD transverse to the measuringaxis direction MA, and are arranged periodically at a scale pitch P_(SF)along the measuring axis direction MA. The illumination source 520comprises a light source 530 that outputs light 534′, and a structuredillumination generating portion 533 configured to input the light 534′and output structured illumination 534″ to an illumination region IR atthe scale plane SP, where the structured illumination 534″ comprises anillumination fringe pattern IFP comprising fringes that are narrow alongthe measuring axis direction MA and elongated along an illuminationfringe direction IFD oriented transverse to the measuring axis directionMA at a nonzero illumination fringe yaw angle ψ relative to the gratingbar direction GBD. The light source 530 comprises a point source 531 anda collimating lens 532. The point source 531 outputs light 534 to thecollimating lens which then collimates the light 534 to provide thelight 534′. The nonzero illumination fringe yaw angle ψ may be achievedin various implementations by rotating one or more elements of thestructured illumination generating portion 533 (e.g., one of theelements 540 and/or 550) about the Z axis, to a desired angle relativeto the Y axis. In some embodiments, the nonzero illumination fringe yawangle ψ may also be achieved or augmented by rotating the grating bardirection GBD about the Z axis, to a desired angle relative to the Yaxis.

The photodetector configuration 560 comprises a set of N spatial phasedetectors arranged periodically at a detector pitch PD (shown in FIG. 6)along a detected fringe motion direction DFMD transverse to themeasuring axis direction MA, wherein each spatial phase detector isconfigured to provide a respective spatial phase detector signal and atleast a majority of the respective spatial phase detectors extend over arelatively longer dimension along the measuring axis direction MA andare relatively narrow along the detected fringe motion direction DFMDtransverse to the measuring axis, and the set of N spatial phasedetectors are arranged in a spatial phase sequence along the detectedfringe motion direction DFMD, as described in greater detail below withreference to FIGS. 8, 9A and 9B.

The scale 510 is configured to input the illumination fringe pattern atthe illumination region IR and output scale light components along ascale light path SCLP to form the detector fringe pattern 535 at thephotodetector configuration 560. The detector fringe pattern 535comprises periodic high and low intensity bands that extend over arelatively longer dimension along the measuring axis direction MA andare relatively narrow and periodic with a detected fringe period PDFalong the detected fringe motion direction DFMD transverse to themeasuring axis direction MA, as described in greater detail below withreference to FIG. 6. As a way of describing their orientation, the bandsextend over a relatively longer dimension along the measuring axisdirection MA, but in various implementations this does not mean they arerequired to be aligned along the measuring axis direction. In variousexemplary implementations, the bands may be aligned at a moderate orsmall angle relative to the measuring axis direction, as explained belowwith reference to FIG. 6.

The detected fringe period PDF and the detected fringe motion directionDFMD transverse to the measuring axis direction MA depend at leastpartially on the nonzero illumination fringe yaw angle ψ, as outlinedbelow with reference to FIG. 7. The high and low intensity bands movealong the detected fringe motion direction DFMD transverse to themeasuring axis direction MA as the scale 510 displaces along themeasuring axis direction MA. The photodetector configuration 560 isconfigured to detect a displacement of the high and low intensity bandsalong the detected fringe motion direction DFMD transverse to themeasuring axis direction MA and provide respective spatial phasedisplacement signals that are indicative of the scale displacement.

In the implementation shown in FIG. 5, the structured illuminationgenerating portion 533 comprises a first illumination source lightdiffraction grating 540 and a second illumination source lightdiffraction grating 550. In some implementations, the first illuminationsource light diffraction grating 540 and the second illumination sourcelight diffraction grating 550 may be phase gratings. Phase gratingsprovide better power efficiency by reducing light loss.

A contamination and defect resistant optical encoder configuredaccording to the principles described with respect to FIG. 5 throughFIG. 9B will provide a simple design which may be tolerant tocontaminants (e.g., wirebonding contamination) which are as large as 100micrometers and scale defects which are as large as 300 micrometers.Contaminants or defects on a scale that are similar in size or largerthan the detection fringe period will typically produce a common modeerror component on adjacent spatial phase detectors which may becanceled out in signal processing (e.g., quadrature processing). Thatis, the effect of contamination moving along the measuring axisdirection will tend to be shared across adjacent spatial phasedetectors, and will move along the measuring axis direction on thoseadjacent spatial phase detectors as the scale or readhead configurationdisplace along the measuring axis direction. Because the contaminationeffect is a common mode effect across adjacent spatial phase detectors,and because the spatial phase detectors are relatively elongated over adimension along the measuring axis direction that may substantiallyexceed the size of the contamination effect, the effect of thecontamination on the displacement signal accuracy may be substantiallymitigated. Another advantage is that in the case of any residualnon-common mode error, as the photodetector configuration 560 displacesrelative to the scale 510, portions of the detector fringe pattern 535corresponding to a defect will move very slowly from one spatial phasedetector to another, which allows for more effective compensation ofspatial phase displacement signals. Such an encoder does not requirecomplex signal processing to provide tolerance to contamination anddefects. Spatial phase displacement signals provided by the set of Nspatial phase detectors may be processed according to standardtechniques known to one skilled in the art.

FIG. 6A is a diagram schematically representing a first view of scalelight components SL1 and SL2 that form a detector fringe pattern 635similar or identical to the detector fringe pattern 535 shown proximateto a photodetector configuration 660 which is similar to thephotodetector configuration 560 in FIG. 5. The detector fringe pattern635 may be provided by an optical encoder similar to the optical encoderconfiguration 500 outlined with reference to FIG. 5. FIG. 6A shows across section of the scale light which forms the detector fringe pattern635 in a plane defined by a measuring axis direction MA and a scalelight path SCLP as previously shown with respect to FIG. 5. As shown inFIG. 6A, the scale light components comprise a first scale lightcomponent SL1 and a second scale light component SL2 (indicated bydashed lines representing high intensity bands) which each compriseparallel rays, where the parallel rays of the first scale lightcomponent SL1 are along a direction with an opposite angular orientationwith respect to the scale light path SCLP. The first scale lightcomponent SL1 and the second scale light component SL2 overlap to formthe detector fringe pattern 635, according to known principles. Thefirst scale light component SL1 and second scale light component SL2 maybe formed from different diffractive orders from a structuredillumination generating portion. The detector fringe pattern 635comprises dark or low intensity interference bands 635D indicated bybold lines, and light or high intensity interference bands 635Lindicated by dashed outlines.

FIG. 6B is a diagram schematically representing a second view of scalelight components SL1 and SL2 that form the fringe pattern 635. FIG. 6Ashows a cross section of the detector fringe pattern 635 in a planedefined by a measuring axis direction MA and a Y direction as previouslyshown with respect to FIG. 5, which is proximate to the photodetectorconfiguration 660. The detector fringe pattern 635 comprises dark or lowintensity interference bands 635D indicated by bold lines and light orhigh intensity interference bands 635L indicated by dashed outlines,which are periodic with a detected fringe period PDF along the detectedfringe motion direction DFMD, as shown in FIG. 6B. The detected fringemotion direction is generally transverse to the direction of theinterference bands 635D and 635L, with a slight rotation equal to thenonzero illumination fringe yaw angle ψ relative to the Y direction.

FIG. 7 is a graph 700 of properties of a contamination and defectresistant optical encoder similar to the optical encoder configuration500 represented in FIG. 5 and FIG. 6, including a detected fringe periodPDF versus an illumination fringe yaw angle ψ. The graph 700 shows datafor a contamination and defect resistant optical encoder which comprisesa structured illumination generating portion with a first illuminationsource light diffraction grating having a grating pitch P₁, a secondillumination source light diffraction grating having a pitch P₂, and ascale having a scale pitch P_(SF), which satisfies the expression:

$\begin{matrix}{{\frac{1}{P_{2}} - \frac{1}{P_{1}}} = \frac{1}{P_{SF}}} & (1)\end{matrix}$

The detected fringe period PDF then relates to the illumination fringeyaw angle ψ by the expression:

$\begin{matrix}{{PDF} = \frac{P_{SF}}{4\;{\sin\left( {\psi/2} \right)}}} & (2)\end{matrix}$

It is generally desirable for a contamination and defect resistantoptical encoder to be configured such that the detected fringe periodPDF is large (e.g., greater than 7 micrometers, or in someimplementations, greater than 40 micrometers), which requires a smallvalue of the illumination fringe yaw angle ψ (e.g., less than 7degrees). A larger detected fringe period PDF provides better toleranceto measurement errors from misalignment between a scale, a photodetectorconfiguration, and an illumination source. Errors arising from pitch androll of a scale relative to an illumination source and/or aphotodetector configuration are inversely proportional to the detectedfringe period PDF. Therefore, a larger detected fringe period PDF willprovide better robustness to measurement errors caused by scalewaviness.

FIG. 8 is a schematic diagram 800 of one exemplary photodetectorconfiguration 860 usable in a contamination and defect resistant opticalencoder which is similar to the optical encoder configuration 500represented in FIG. 5 and FIG. 6, wherein the photodetectorconfiguration includes spatial phase detectors that are elongatedapproximately or roughly along the measuring axis direction and arrangedperiodically transverse to the measuring axis direction. Similarreferences numbers 8XX in FIGS. 8 and 5XX in FIG. 5 may refer to similarelements unless otherwise indicated by context or description.

The photodetector configuration 860 comprises a set of N spatial phasedetectors arranged in a spatial phase sequence along the detected fringemotion direction DFMD, where N is an integer that is at least 6 and thespatial phase sequence comprises two outer spatial phase detectors at astart and end of the sequence along the direction transverse to themeasuring axis direction MA and an interior group of spatial phasedetectors located between the two outer spatial phase detectors. Eachspatial phase detector in the interior group is preceded and followed inthe spatial phase sequence by spatial phase detectors that haverespective spatial phases that are different from that spatial phasedetector and different from each other. Each spatial phase detectorcomprises scale light receptor areas that are spatially periodic alongthe detected fringe motion direction DFMD and positioned correspondingto a respective spatial phase of that spatial phase detector relative tothe periodic scale light pattern. Each spatial phase detector in theinterior group is preceded and followed in the spatial phase sequence byspatial phase detectors that have respective spatial phases that aredifferent from that spatial phase detector and different from eachother.

In some implementations, the set of N spatial phase photodetectors maycomprise at least M subsets of spatial phase detectors, where M is aninteger that is at least 2, and wherein each of the M subsets includesspatial phase detectors that provide each of the respective spatialphases included in the set of N spatial phase photodetectors. In someimplementations, M may be at least 4. In some implementations, M may beat least 6. In some implementations, each of the M subsets of spatialphase detectors may comprise spatial phase detectors that provide thesame respective spatial phases arranged in the same subset spatial phasesequence. FIG. 8 shows an implementation with M subsets of spatial phasedetectors indicated as S₁ through S_(M). The subset S₁ comprises spatialphase detectors SPD_(1A), SPD_(1B), SPD_(1C), and SPD_(1D). The subsetS₂ comprises spatial phase detectors SPD_(2A), SPD_(2B), SPD₂, andSPD_(2D). The subset S_(M) comprises spatial phase detectors SPD_(MA),SPD_(MB), SPD_(MC), and SPD_(MD).

In the implementation shown in FIG. 8, the spatial phase sequence isindicated by spatial phase detectors including subscript indices A, B,C, and D (e.g., the spatial phase detectors SPD_(1A), SPD_(1B),SPD_(1C), and SPD_(1D)). The spatial phase detectors with subscriptindices A and D are the two outer spatial phase detectors at the startand end of each instance of the spatial phase sequence. The spatialphase detectors with subscript indices B and C are the interior groups.

The spatial phase detectors SPD_(1A), SPD_(1B), SPD_(1C), and SPD_(1D)output respective spatial phase detector signals A₁, B₁, C₁, and D₁. Thespatial phase detectors SPD_(2A), SPD_(2B), SPD_(2c), and SPD_(2D)output respective spatial phase detector signals A₂, B₂, C₂, and D₂. Thespatial phase detectors SPD_(MA), SPD_(MB), SPD_(MC), and SPD_(MD)output respective spatial phase detector signals A_(M), B_(M), C_(M),and D_(M).

In some implementations, such as the implementation shown in FIG. 8, Nis at least 8 and each subset of spatial phase detectors may comprise 4spatial phase detectors having respective spatial phases separated by 90degrees. In alternative implementations, each subset of spatial phasedetectors may comprise 3 spatial phase detectors having respectivespatial phases separated by 120 degrees.

In the implementation shown in FIG. 8, the photodetector configuration860 includes connections configured to combine spatial phase detectorsignals corresponding to the same respective spatial phase and to outputeach such combination as a respective spatial phase position signal. Thephotodetector configuration 860 is configured to output 4 spatial phaseposition signals corresponding to spatial phases separated by 90degrees. Spatial phase signals with the same letter designation (e.g.,A₁, A₂, and A_(M)) are combined (e.g., summed) to provide spatial phasesignals ΣA, ΣB, ΣC, and D. In alternative implementations, aphotodetector configuration may be configured to output 3 spatial phaseposition signals corresponding to spatial phases separated by 120degrees. In either case, spatial phase position signals may be furtherutilized to determine displacement signals, e.g., through quadrature orthree phase signal processing.

In some implementations, a separation distance YSEP between the scalelight receptor areas of each adjacent pair of the N spatial phasedetectors along the detected fringe motion direction DFMD may be at most25 micrometers. In some implementations, the separation distance YSEPbetween the scale light receptor areas of each adjacent pair of the Nspatial phase detectors is the same along the detected fringe motiondirection DFMD.

FIG. 8 additionally shows a detector axis DA in relation to themeasuring axis direction MA. The detector axis is a direction parallelto the specific elongation direction of the spatial phase detectors. Ingeneral, it is desirable that the detector axis DA is orthogonal (orclose to orthogonal) to the detected fringe motion direction DFMD,although it is not required that it be precisely so, subject to thecondition that good displacement signals may be obtained. Therefore, insome implementations the detector axis may be rotated with respect tothe measuring axis direction MA by an angle α, particularly if thedetected fringe motion direction DFMD is not perpendicular to themeasuring axis direction MA. Since it is desirable to use a smallillumination fringe yaw angle ψ (as described with respect to FIG. 7),the angle α may be rather small, and in some cases with a very smallvalue of the illumination fringe yaw angle ψ, it may not even benecessary to rotate the detector axis D with respect to the measuringaxis direction MA.

FIG. 9A is a detailed schematic diagram of a section of anotherexemplary photodetector configuration 960A of a contamination and defectresistant optical encoder 900A which is similar to the photodetectorconfiguration shown in FIG. 8. For simplicity, FIG. 9A only shows onesubset of spatial phase detectors S₁ with two spatial phase detectorsSPD_(1A) and SPD_(1B). It should be appreciated that the photodetectorconfiguration 960A may comprise more spatial phase detectors accordingto the principles disclosed herein, but only two are shown forsimplicity. In the implementation shown in FIG. 9A, each of the Nspatial phase detectors (e.g., spatial phase detectors SPD_(1A) andSPD_(1B)) comprises a photodetector (e.g., photodetectors PD_(1A) andPD_(1B) indicated by dashed lines) covered by a spatial phase mask(e.g., phase masks PM_(1A) and PM_(1B)) that blocks the photodetectorfrom receiving the periodic scale light pattern except through openingsincluded in the spatial phase mask. In this case, the scale lightreceptor areas comprise areas of the photodetectors (e.g., thephotodetectors PD_(1A) and PD_(1B)) that are exposed through theopenings in the respective spatial phase masks (e.g., the spatial phasemasks PM_(1A) and PM_(1B)). In the implementation shown in FIG. 9A, thescale light receptor areas (i.e., the openings) of the phase maskPM_(1B) are offset relative to the scale light receptor areas of thephase mask PM_(1A) along the detected fringe motion direction DFMD by 90degrees. It should be appreciated that the while the spatial phase masksPM_(1A) and PM_(1B) are schematically illustrated as separate portionsin FIG. 9A, in some implementations, they may be convenientlyconstructed with the same material in the same process to eliminate anypotential positioning errors.

FIG. 9B is a detailed schematic diagram of a section of anotherexemplary photodetector configuration 960B of a contamination and defectresistant optical encoder 900B which is similar to the photodetectorconfiguration 860 shown in FIG. 8. For simplicity, FIG. 9B only showsone subset of spatial phase detectors S₁′ with two spatial phasedetectors SPD_(1A)′ and SPD_(1B)′. It should be appreciated that thephotodetector configuration 960B may comprise more spatial phasedetectors according to the principles disclosed herein, but only two areshown for simplicity. In the implementation shown in FIG. 9B, each ofthe N spatial phase detectors (e.g., spatial phase detectors SPD_(1A)′and SPD_(1B)′) comprises a periodic array of electrically interconnectedphotodetector areas that receive the periodic scale light pattern. Inthis case, the scale light receptor areas comprise the photodetectorareas of the periodic array of photodetectors. In the implementationshown in FIG. 9B, the photodetector areas of the spatial phase detectorSPD_(1B)′ are offset relative to the photodetector areas of the spatialphase detector SPD_(1A)′ along the detected fringe motion direction DFMDby 90 degrees of spatial phase shift.

In some implementations of photodetectors which are similar to thephotodetector configurations 960A or 960B, it is advantageous for eachof the N spatial phase detectors to comprise an even number of scalelight receptor areas. Zero order components of scale light may cause avariation in intensity between alternating fringes within the scalelight. Therefore, having an even number of scale light receptor areaswill average out this variation.

While preferred implementations of the present disclosure have beenillustrated and described, numerous variations in the illustrated anddescribed arrangements of features and sequences of operations will beapparent to one skilled in the art based on this disclosure. Variousalternative forms may be used to implement the principles disclosedherein. In addition, the various implementations described above can becombined to provide further implementations. All the U.S. patents andU.S. patent applications referred to in this specification are herebyincorporated herein by reference, in their entirety. Aspects of theimplementations can be modified, if necessary to employ concepts of thevarious patents and applications to provide yet further implementations.

These and other changes can be made to the implementations in light ofthe above-detailed description. In general, in the following claims, theterms used should not be construed to limit the claims to the specificimplementations disclosed in the specification and the claims, butshould be construed to include all possible implementations along withthe full scope of equivalents to which such claims are entitled.

What is claimed is:
 1. A contamination and defect resistant opticalencoder configuration for providing displacement signals, comprising: ascale that extends along a measuring axis direction, the scalecomprising a scale grating comprising grating bars arranged in a scaleplane that is nominally parallel to the measuring axis direction,wherein the grating bars are narrow along the measuring axis directionand elongated along a grating bar direction transverse to the measuringaxis direction, and are arranged periodically at a scale pitch P_(SF)along the measuring axis direction; an illumination source comprising alight source that outputs light, and a structured illuminationgenerating portion configured to input the light and output structuredillumination to an illumination region at the scale plane where thestructured illumination comprises an illumination fringe patterncomprising fringes that are narrow along the measuring axis directionand elongated along an illumination fringe direction oriented transverseto the measuring axis direction at a nonzero illumination fringe yawangle relative to the grating bar direction; and a photodetectorconfiguration comprising a set of N spatial phase detectors arrangedperiodically at a detector pitch PD along a detected fringe motiondirection transverse to the measuring axis direction, wherein eachspatial phase detector is configured to provide a respective spatialphase detector signal and at least a majority of the respective spatialphase detectors extend over a relatively longer dimension along themeasuring axis direction and are relatively narrow along the detectedfringe motion direction transverse to the measuring axis direction, andthe set of N spatial phase detectors are arranged in a spatial phasesequence along the detected fringe motion direction; wherein: the scalegrating is configured to input the illumination fringe pattern at theillumination region and output scale light that forms a fringe patternat the photodetector configuration, the fringe pattern comprisingperiodic high and low intensity bands that extend over a relativelylonger dimension along the measuring axis direction and are relativelynarrow and periodic with a detected fringe period PDF along the detectedfringe motion direction transverse to the measuring axis direction; thedetected fringe period PDF and the detected fringe motion directiontransverse to the measuring axis direction depend at least partially onthe nonzero illumination fringe yaw angle; the high and low intensitybands move along the detected fringe motion direction transverse to themeasuring axis direction as the scale grating displaces along themeasuring axis direction, and the photodetector configuration isconfigured to detect a displacement of the high and low intensity bandsalong the detected fringe motion direction transverse to the measuringaxis direction and provide respective spatial phase displacement signalsthat are indicative of the scale displacement.
 2. The contamination anddefect resistant optical encoder configuration of claim 1, wherein thestructured illumination generating portion comprises a firstillumination source light diffraction grating and a second illuminationsource light diffraction grating.
 3. The contamination and defectresistant optical encoder configuration of claim 2, wherein the firstillumination source light diffraction grating and the secondillumination source light diffraction grating are phase gratings.
 4. Thecontamination and defect resistant optical encoder configuration ofclaim 1, wherein N is an integer that is at least
 6. 5. Thecontamination and defect resistant optical encoder configuration ofclaim 4, wherein: the spatial phase detectors are arranged in thespatial phase sequence along the detected fringe motion direction, whereN is an integer that is at least 6 and the spatial phase sequencecomprises two outer spatial phase detectors at a start and end of thespatial phase sequence along the detected fringe motion directiontransverse to the measuring axis direction and an interior group ofspatial phase detectors located between the two outer spatial phasedetectors; each spatial phase detector in the interior group is precededand followed in the spatial phase sequence by spatial phase detectorsthat have respective spatial phases that are different from that spatialphase detector and different from each other; and each spatial phasedetector comprises scale light receptor areas that are spatiallyperiodic along the detected fringe motion direction and positionedcorresponding to a respective spatial phase of that spatial phasedetector relative to a periodic scale light pattern.
 6. Thecontamination and defect resistant optical encoder configuration ofclaim 5, wherein the set of N spatial phase detectors comprises at leastM subsets of spatial phase detectors, where M is an integer that is atleast 2, and wherein each of the M subsets includes spatial phasedetectors that provide each of the respective spatial phases included inthe set of N spatial phase detectors.
 7. The contamination and defectresistant optical encoder configuration of claim 6, wherein M is atleast
 4. 8. The contamination and defect resistant optical encoderconfiguration of claim 6, wherein M is at least
 6. 9. The contaminationand defect resistant optical encoder configuration of claim 6, whereineach of the M subsets of spatial phase detectors comprises spatial phasedetectors that provide the same respective spatial phases arranged inthe same subset spatial phase sequence.
 10. The contamination and defectresistant optical encoder configuration of claim 9, wherein each subsetof spatial phase detectors comprises 3 spatial phase detectors havingrespective spatial phases separated by 120 degrees.
 11. Thecontamination and defect resistant optical encoder configuration ofclaim 9, wherein N is at least 8 and each subset of spatial phasedetectors comprises 4 spatial phase detectors having respective spatialphases separated by 90 degrees.
 12. The contamination and defectresistant optical encoder configuration of claim 5, wherein thephotodetector configuration includes connections configured to combinespatial phase detector signals corresponding to the same respectivespatial phase and to output each such combination as a respectivespatial phase position signal.
 13. The contamination and defectresistant optical encoder configuration of claim 12, wherein thephotodetector configuration is configured to output 3 spatial phaseposition signals corresponding to spatial phases separated by 120degrees.
 14. The contamination and defect resistant optical encoderconfiguration of claim 12, wherein the photodetector configuration isconfigured to output 4 spatial phase position signals corresponding tospatial phases separated by 90 degrees.
 15. The contamination and defectresistant optical encoder configuration of claim 5, wherein a separationdistance YSEP between the scale light receptor areas of each adjacentpair of the N spatial phase detectors along the detected fringe motiondirection is at most 25 micrometers.
 16. The contamination and defectresistant optical encoder configuration of claim 5, wherein a separationdistance YSEP between the scale light receptor areas of each adjacentpair of the N spatial phase detectors is the same along the detectedfringe motion direction.
 17. The contamination and defect resistantoptical encoder configuration of claim 5, wherein each of the N spatialphase detectors comprises a photodetector covered by a spatial phasemask that blocks the photodetector from receiving the periodic scalelight pattern except through openings included in the spatial phasemask, wherein the scale light receptor areas comprise areas of thephotodetector that are exposed through the openings in the spatial phasemask.
 18. The contamination and defect resistant optical encoderconfiguration of claim 5, wherein each of the N spatial phase detectorscomprises a periodic array of electrically interconnected photodetectorareas that receive the periodic scale light pattern, wherein the scalelight receptor areas comprise the photodetector areas of the periodicarray of photodetectors.
 19. The contamination and defect resistantoptical encoder configuration of claim 5, wherein each of the N spatialphase detectors comprises an even number of scale light receptor areas.20. The contamination and defect resistant optical encoder configurationof claim 1, wherein the detected fringe period PDF is at least 40micrometers.